Schneider Electric Brands

Busway Systems

Class 5600

CONTENTS

Description PageProduct Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Layout and Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Installation, Special Features, and Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Electrical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31225 A600 A Catalog Numbering System/Physical Data . . . . . . . . . . . . . . . . . . . . . 33800 A5000 A Catalog Numbering System/Physical Data . . . . . . . . . . . . . . . . . . . . 42Catalog Numbering System/Plug-In Units (Bus Plugs) . . . . . . . . . . . . . . . . . . . . . 59Suggested Busway Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72100 A Plug-In Busway. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74100 A Plug-In Busway Suggested Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 79POWER-ZONE Metal-Enclosed Busway. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80POWER-ZONE Metal-Enclosed Busway Suggested Specifications. . . . . . . . . . . . . 86

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PRODUCT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Sandwich Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Totally Enclosed Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Compact Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Dielectric Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10VISI-TITE One Bolt Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10EZ JOINT PAK Connector Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Labor Savings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Tie Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Internal Smoke/Gas Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Short Circuit Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Voltage Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Outdoor Busway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Universal Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Integral Ground Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Plug-in Busway 225 A600 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Plug-in Busway 800 A5000 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Indoor Feeder Busway 800 A5000 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Outdoor Feeder Busway 800A5000 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

APPLICATION DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17The Four Types of Busway Runs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Service Entrance Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Plug-In Type Vertical Riser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Plug-In Type Horizontal Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Feeder Type Tie Run. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Service Entrance Runs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Service Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Transformer Taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Bussed Transformer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Other Service Entrance Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Plug-in Busway Horizontal Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Plug-in Risers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Riser Installation and Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Special Manufacturers Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Plug-In Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Hangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Feeder Runs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Busway Through Walls and Floors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 19972001 Schneider Electric All Rights Reserved

4Busway SystemsContentsLAYOUT AND MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26Layout And Measurement of Busway Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Known Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

INSTALLATION, SPECIAL FEATURES, AND SERVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Installation Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Painting Installed Busway Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Hanger Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Maintenance Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Special Busway Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Special Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Low Current Density Busway. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Riser Plug-in Busway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Drip Resistant to IP-54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Busway Measuring and Layout Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Emergency Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30Missing Link Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30Busway Quick Ship Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30How To Properly Measure Your Missing Link(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

ELECTRICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Electrical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Voltage Drop Sample Calculations (60 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Sample No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Sample No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Voltage Drop Data (60 Hz At Rated Load) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32225 A600 A CATALOG NUMBERING SYSTEM/PHYSICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . 33

I-LINE Busway Catalog Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Straight Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Joint Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Cable Tap Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Tees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Elbows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Expansion Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Unfused Reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Flanged End Cutout And Drilling Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Flanged End Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Flatwise Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Edgewise Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Sway Brace Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Vertical Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Vertical Spring Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39End Closure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Wall And Floor Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Required Wall Openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Busway Catalog Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

800 A5000 A CATALOG NUMBERING SYSTEM/PHYSICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . 42Cross SectionsPlug-In and Indoor Feeder Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 19972001 Schneider Electric All Rights Reserved 09/01

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Busway Systems

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Cross SectionsFittings and All Outdoor Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Straight LengthsFeeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Straight LengthsPlug-in (Indoor Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Qwik Flange (Indoor Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Qwik Flange (Indoor Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Flanged End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Flanged End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Qwik Flange And Flanged End Termination Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Detail of Phase Bussing Connections in a Switchboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Elbows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Offset Elbows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Double Elbows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Cable Tap BoxEnd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Cable Tap BoxCenter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Cable Tap BoxBolt On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Unfused Reducer (Indoor Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Expansion Fitting (Indoor Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Tees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Service Head Flatwise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Transformer Tap (One 3 Transformer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Service Head Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Straight Length With Flanged Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Roof Flange Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Transformer Tap (Three 1 Transformers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Adapter (Indoor Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Phase Transition (Indoor Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55HangerHorizontal Flatwise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56HangerHorizontal Flatwise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Hanger Horizontal Edgewise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56HangerVertical Fixed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57HangerVertical Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Wall and Floor Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58End Closure (Indoor Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

CATALOG NUMBERING SYSTEM/PLUG-IN UNITS (BUS PLUGS) . . . . . . . . . . . . . . . . . . . . . . . . 59Plug-In Catalog Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Type of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Fusible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Plug-In Device Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Special Purpose Plug-In Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Horsepower Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Interrupting Capacity of Fusible Switch Plug-In Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Interrupting Capacity of Circuit Breaker Plug-In Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Required Clearances for Plug-In Unit Mounting (Check These Dimensions Carefully Before Installing Busway Lengths) . . . . . . . . . . . . . . . . . . 62Vertical Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Fusible Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625 19972001 Schneider Electric All Rights Reserved

6Busway SystemsContentsCircuit Breaker Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62Fusible Switch Plug-In Units30 A100 A (Type PQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Fusible Switch Plug-In Unit200 A (Type PQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Fusible Switch PlugIn Unit 200 A (Type PS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Fusible Switch PlugIn Unit 400 A (Type PBQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Fusible Switch Plug-In Unit 600 A (Type PBQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Fusible Switch Plug-In Unit 400 A (Type PBQA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Fusible Switch Bolt-On Units 800 A1600 A (Type PTQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Circuit Breaker Plug-In Units15 A250 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67I-LIMITER Current-Limiting Circuit Breaker Plug-In Units15 A250 A . . . . . . . . . . . . . . . . . 67I-LIMITER Current-Limiting Circuit Breaker Plug-In Units 300 A600 A . . . . . . . . . . . . . . . .68Circuit Breaker Plug-In Units250 A400 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Circuit Breaker Plug-In Units300 A600 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Circuit Breaker Bolt-On Units500 A1600 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Combination Fusible Switch and StarterLighting ContactorContactor . . . . . . . . . . . . . . . . . 70Ground Detector and Neutralizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Combination Circuit Breaker And Starter Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

SUGGESTED BUSWAY SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

1.1 Quality Assurance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721.2 Regulatory Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721.3 Delivery, Storage, and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

2.0 Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 722.1 Manufacturers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 722.2 Manufactured Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .722.3 Basic Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 722.4 Support of Busway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 732.5 Voltage Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 732.6 Plug-In Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 732.7 Plug-In Unit Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

3.0 Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 733.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

100 A PLUG-IN BUSWAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74UL Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Conductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74Ground Bus (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Bus Bar Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Short Circuit Bracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Hangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Voltage Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 19972001 Schneider Electric All Rights Reserved 09/01

09/01

Busway Systems

Contents

Straight Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Joint Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Busway Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Cross Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Elbows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Tees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Hangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Wall Flange End Closure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77End Closure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Outer Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Circuit Breaker Plug-In Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Cable Tap Boxes Plug-In Cable Tap Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Floor Operated Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

100 A PLUG-IN BUSWAY SUGGESTED SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 791.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

1.1 Quality Assurance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 791.2 Regulatory Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

2.0 Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 792.1 Manufactured Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 792.2 Basic Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 792.3 Bus Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 792.4 Support of Busway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 792.5 Plug-In Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

POWER-ZONE METAL-ENCLOSED BUSWAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Housing Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Housing Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Conductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Conductor Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83POWER-ZONE Bus Standard Construction: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Bus Bar Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Bus Bar Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Bus Bar Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Housing Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Bus Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Layout and Pricing Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Fitting Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Transformer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Generator Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Bushing Box (Weatherhead) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Ground Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Wall Entrance Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Equipment Entrance Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Expansion Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Housing Bellows (Misalignment) Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 847 19972001 Schneider Electric All Rights Reserved

8Busway SystemsContentsFlanged Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Cable Tap Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Supporting Steel (Hangers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Hazardous or Seismic Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

General Pricing Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Weatherproof Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Typical Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

POWER-ZONE METAL-ENCLOSED BUSWAY SUGGESTED SPECIFICATIONS . . . . . . . . . . . . . . 861.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

1.1 Section Includes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 861.2 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

2.0 Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 862.1 Manufacturers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 862.1 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 862.3 Phase Bus Bars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 862.4 Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 872.5 Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 19972001 Schneider Electric All Rights Reserved 09/01

Busway Systems

Product Description

General

I-LINE Busway manufactured by Square D offers a complete line of compatible, sandwich-type feeder and plug-in busway lengths and fittings. It allows maximum flexibility, ease of installation, and offers electrical efficiency in the distribution of low voltage power for both commercial and industrial applications.

I-LINE busway has been used to supply power in thousands of installations throughout the world for more than three decades. Our broad range of I-LINE busway products include: I-LINE Plug-In style from 225 A600 A with aluminum or copper conductors; I-LINE II Plug-in and Feeder styles from 800 A to 4000 A with aluminum conductors, and to 5000 A with copper conductors. I-LINE and I-LINE II busways are constructed in three-pole and four-pole full neutral configurations for system voltages to 600 Volts and are rated to allow 100% of the current to flow continuously.

Busway installation is quick and easy. The compact, totally enclosed design is lightweight and easy to handle. Labor studies have shown that a 75% savings in installation time is not uncommon when comparing I-LINE busway with cable and conduit installations. This significant reduction in installation time can result in total installed cost for busway being significantly lower than other distribution methods.In addition, a wide variety of busway components and plug-in units are available from stock for fast delivery.

When you need busway, select the bestI-LINE busway. Our design and construction has been time-tested in many years of use throughout the world. No matter how you compare, I-LINE busway is your solid first choice!

Sandwich ConstructionI-LINE feeder and plug-in busway both utilize sandwich-type construction to provide superior voltage drop characteristics, even at low power factors.

Steel housing sides and aluminum tops and bottoms have been carefully designed to reduce component weight and minimize the hysteresis and eddy current losses that are common in all steel housings.Plug-in busway ratings that utilize two or three bus bars per phase have a phase paralleling feature at the joint assembly of each straight length. This helps equalize bus bar loading when plugs are mounted on one side only.The plug-in housing has notches along the top rail for easy alignment and installation of plug-in units.Within the same ampere rating, all I-LINE II busway lengths and fittings are fully compatible between feeder and plug-In styles using standard universal tie channels (housing splice plates) supplied with each component.

Totally Enclosed HousingVentilated busway depends on free air movement through a perforated housing to cool the bus bars. Unless mounted in its preferred position (maximum bus bar cooling), ventilated busway must be derated. Ventilated housing also permits dirt accumulation and offers limited protection of bus bars due to open ventilating slots in the housing. I-LINE busway has a modern totally enclosed housing design requiring no derating regardless of mounting position. Because the housing has no ventilating holes, the entry of dirt and possibility of accidental contact with bus bars is greatly reduced.

Compact Size

I-LINE II busway is compact. The small size means it may be used in locations where feeder circuits would not otherwise be possible. Efficient use of light-weight raw materials is an additional factor in I-LINE busways compact design.

Finish

I-LINE busway housing appearance has been further enhanced by the addition of a multi-million dollar cationic electro-deposition paint system to our production facility. I-LINE busway users get a tough, durable uniform E-Coat epoxy paint finish, making their busway installations functional and attractive for years to come.

Insulation

All bus bars are insulated using Class B rated (130 C (266 F) vendor certified) materials to prolong insulation life. I-LINE busway insulation consists of two layers of heat-formed polyester film surrounding each bus bar. On plug-in busway lengths, all insulation is notched at the openings to allow plug-in unit mounting.909/01 19972001 Schneider Electric All Rights Reserved

Busway Systems

Product Description

I-LINE II busway uses the same two layers of polyester film to insulate the bus bars in indoor busway while outdoor busway utilizes powder-coated epoxy insulation for the bus bars. Both types of insulation offer high quality dielectric strength and long life expectancy.

PlatingBus bars for I-LINE and I-LINE II busway are plated to ensure low surface-to-surface contact resistance and to minimize surface corrosion. Aluminum bus bars are electroplated with a coat of tin after preparation with the ALSTAN 70 process. Copper bus bars are plated with a layer of silver that is flashed onto the surface of the bus bar.

Dielectric TestingUL and CSA require a one-time dielectric test for all new busway designs prior to certification. This test, at two times rated voltage plus 1000 Vac (2200 Vac), is intended to confirm the integrity of the insulation system. I-LINE busway passes this test.

Every length and fitting of our busway must also pass a 7500 Vdc hi-pot test before shipment from the factory. This additional test helps ensure the highest quality busway possible for our customers.

VISI-TITE One Bolt Joint

I-LINE busway incorporates the one bolt joint principle. This joint design uses a high-strength (Grade 5) VISI-TITE bolt to provide a clamping force of over 4000 pounds. The force is distributed over the contact area by a pair of large diameter, spring steel cupped conical washers. On higher ampere ratings (2000 A or above) two or three joint bolts are used-one for each set of bus bars. Our one bolt principle replaces older designs which required up to 32 nuts, bolts, and washers for each set of bus bars. The VISI-TITE torque indicating joint bolt is standard on all busway joints. Insulated and at ground potential, the bolt and nut are both captive to reduce installation time.

Fast, accurate torquing is a snap with VISI-TITE double- headed bolts. Theres no need for a torque wrench. Use any long handled wrench to tighten the outer bolt head until it twists off and releases a red plastic warning disc. Any disc remaining during inspection indicates an improperly torqued joint. For maintenance of the joint or when busway is relocated, the VISI-TITE bolt should be tightened to 70 lb-ft +/- 10 lb-ft (94.92 Nm +/- 13.56 Nm) with a torque wrench.

EZ JOINT PAK Connector Assembly

I-LINE II busway offers an improved single bolt joint package which can be removed and replaced with an isolation joint pak to electrically isolate busway sections for load shifting and maintenance. It can also be relocated to the opposite end of a length to take care of last minute job changes. The EZ JOINT PAK Connector Assembly is shipped pre-assembled with each I-LINE II busway length or fitting, providing minimum job-site installation labor. And the VISI-TITE bolt is a standard feature on all assemblies.

Labor SavingsI-LINE II busway installs quickly compared to other forms of low voltage power distribution. While material costs may be slightly higher, the labor required to install I-LINE II busway is often much lower. This results in an overall reduction in total installation cost.

Total Installation Cost

MaterialMaterial

LaborLabor

OtherDistribution

Methods

I-LINEBusway 19972001 Schneider Electric All Rights Reserved10

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Busway SystemsProduct Description

1109/01 19972001 Schneider Electric All Rights Reserved

Tie ChannelsI-LINE II busway uses one set of universal tie channels for all ampere ratings of buswayboth feeder and plug-in. This helps speed up busway installation.

Internal Smoke/Gas BarriersContinuous air spaces inside I-LINE II busway housing are closed off with special barriers to help prevent the spread of smoke and gases in the event of a fire in the area of the busway installation. This standard internal barrier allows busway to extend through walls or floors without creating open space for a chimney effect fire path.

I-LINE busway from 225 A600 A requires installation of a special internal barrier for wall or floor penetrations.

Short Circuit StrengthI-LINE busway housing construction gives high short circuit ratings. On some feeder busway, additional short circuit strength is gained by wrapping the bus bar sandwich with epoxy saturated fiberglass tape. This results in ratings of up to 200,000 RMS symmetrical for 4000 A and 5000 A feeder busway.On plug-in busway, molded plug-in opening insulators (or optional high strength insulators) provide additional short circuit strength. Full short circuit bracing extends across the plug-in opening to protect the plug-in connections.Our busway has been tested under actual short circuit conditions at the Square D High Power Laboratory in Cedar Rapids. These tests confirm I-LINE busway can withstand extremely high short circuit levels. Some ratings actually stand up to tests at 200,000 RMS symmetrical amperes!

Voltage DropBecause of its extremely low reactance, I-LINE busway voltage drop is low. This efficient design allows power to be delivered in an installation with the highest efficiency possible. This makes I-LINE busway ideal for efficient power distribution in commercial or industrial facilities.

Outdoor BuswayOutdoor feeder busway is furnished with a housing construction employing a special gasketed design to prevent the entry of rain. Unique engineering and design features allow field installation in any mounting position while still maintaining outdoor integrity. This product symmetry provides for proper installation in all instances. The VISI-TITE bolt is also standard on outdoor busway.

Universal FittingsI-LINE II busway fittings are designed for use with feeder and plug-in busway straight lengths as well as for continuations of service entrance busway runs. The compact universal fittings allow maximum layout flexibility without the need for special built-to-order combination fittings.

QualityAll I-LINE busway products are manufactured in a Square D facility which has been registered by Underwriters Laboratories, Inc. to ISO9001:1994; EN29001:1994; BS5750 Part 1: 1994; ANSI/ASQCQ91:1994.

Integral Ground BusI-LINE II busway (800 A5000 A) is built with an innovative Integral Ground Bus (IGB) system, proven by many years of use on original I-LINE busway installations.In simple terms, IGB utilizes two 1/16-inch thick ground bus bars to form the housing top and bottom. This provides an integral 50% continuous current capacity ground path. Equally important, the two ground bus bars completely encircle the phase conductors and provide a very effective high level ground path for ground faults. Copper integral ground is available as an option.We believe a properly designed ground should be included on all distribution systems. I-LINE II busway includes IGB as a standard feature on every rating from 800 A to 5000 A.(Integral ground bus is available as an option on 225 A600 A busways.)We offer many products and services to fulfill the need for complete and reliable grounding throughout your electrical system. Consult your local sales office for assistance in this very important aspect of proper electrical design.

I-LINE IIBuswayCross SectionIncludingStandard IntegralGround Bus (IGB)

Ground bus/Housing top (1/16-inchAluminum bus bar)

Ground bus/Housing bottom(1/16-inch Aluminumbus bar)

Bus bars

Steel side channel(2) for mechanicalstrength

Top

Continuous bonding betweentop and bottom ground bus

Busway SystemsConstruction

19972001 Schneider Electric All Rights Reserved12

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Plug-in Busway 225 A600 A

1. Integral Ground Bus (IGB)Is furnished as an optional feature for I-LINE busway and rated at 50% capacity of the nameplate Amperage rating of the busway. The conductor is aluminum and is the top part of the housing itself.

2. VISI-TITE BoltIs a double-headed bolt furnished for all joint connectors to ensure proper torque for each connection. A cupped conical washer is also included to ensure equal distri-bution of pressure across the full joint surface area.

3. Plug-in OpeningsIs furnished standard with plug-in openings on 2 ft (61 cm) centers on both sides of I-LINE busway. The openings include a hinged door that covers the opening when it is not in use. A 600 A maximum capability is at each plug-in opening. Hangers for the busway fit without blocking access to the plug-in opening.

4. The EnclosureIs a three-piece formed housing with plug-in openings supported by molded rigid insulators.

NOTE: Insulation for I-LINE busway is two full-length layers of Class B rated (130 C (266 F) vendor certified) polyester film.

Busway Systems

Construction

Plug-in Busway 800 A5000 A

1. Molded plug-in opening insulatorAdds insulation and support at plug-in contact area.

2. EZ JOINT PAK connector assemblyIncludes like-phase connector on higher ampere ratings with more than one conductor per phase (plug-in bus only).

3. Ground jaw for plug-in unitHas a blow-on design similar to phase jaw connection.

4. FittingsIncludes elbows, tees, and flanged ends that are easily removed and refitted with the use of our EZ JOINT PAK assembly without disturbing adjacent lengths.

NOTE: Internal barriers are standard on both feeder and plug-in busway. All interior spaces are barriered to stop hot gases.NOTE: Hangers fit both feeder and plug-in busway without blocking access to openings.NOTE: I-LINE plug-in units (15 A1600 A) fit both original and I-LINE II busway.

NOTE: I-LINE II plug-in busway with sandwich construction also includes features depicted for feeder style on page 14.1309/01 19972001 Schneider Electric All Rights Reserved

Busway Systems

Construction

Indoor Feeder Busway 800 A5000 A

1. Steel housing channelsProvides mechanical strength.2. Molded extra-strength glass fiber interphase barriers.3. EZ JOINT PAK connector assemblyRemovable for

isolation or maintenance. Includes VISI-TITE bolt.4. Steel/aluminum housingReduces hysteresis and eddy

current losses on feeder and plug-in busway.5. Plated aluminum or copper bus bars.6. Surge clamps for added short circuit strength.7. Integral Ground Bus (IGB) Two, 1/16-inch thick aluminum

bus bar. Also serves as top and bottom housing.

a Electrodeposition paint processProvides lasting uniform appearance.

a Housing sizesAre the same for I-LINE II feeder and plug-in busway. Same accessories fit both.

a Insulation Is Class B rated (130 C (266 F) vendor certified) insulation.

a Optional Fiberglass tape and epoxy resinImproves short circuit strength (Type AFH2/CFH2). 19972001 Schneider Electric All Rights Reserved14

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Busway Systemsnactivities complete.1. Joint Covers Two-piece joint cover with quick-fasten nut for speedy installation of the busway.

2. EZ JOINT PAKThe same joint pack used on our indoor I-LINE II busway is continued in our Outdoor Feeder design.

3. Flanged CollarSimple installation of the joint covers is assisted by a smooth flange surface with the joint sealant strip factory installed. Removal of the sealants protective paper covering and installation of the joint covers with the quick fasten nut, seal the joint from contamination by water.

4. Removable Drain PlugThe outdoor feeder design includes removable drain plugs to allow condensation to escape from the joints. These drain plugs should be removed only as described in the installation instructions for outdoor feeder busway.

5. Completed JointThe assembled joint with all installation

NOTE: Supports are required on 5 ft (152 cm) centers for vertical or horizontal mounting. Normally, the support for outdoor busway is in the form of a T-stand type device, which is customer supplied. However, hangers are available from Square D when drop rods can be utilized. Constructio

Outdoor Feeder Busway 800A5000 A 1509/01 19972001 Schneider Electric All Rights Reserved

Busway Systems

Construction

Listed below are the four basic types of busway applications:

Service Entrance Run Plug-In Type Horizontal Run Plug-In Type Vertical Run Feeder Type Tie RunIn addition to the information that is electronically entered into the Product Selectors, the information needed by Oxford to engineer a busway run is listed below. A busway run may consist of more than one type of application.

Notes: (1) For detailed illustrations refer to pages 1727.(2) Lack of all required information causes delays in order processing and can affect the delivery schedule.(3) If additional assistance is required, contact Square D at 1-888-SQUARE D (1-888-778-2733).

Type ofApplication

1 2 3 4 Busway Order Entry Checklist

Order Number: _______________________________________ Completed by: ____________________________________

Field Office: _________________________________________ Date: _____________________________

() = Required Information

SERVICE

HORIZONTAL

VERTICAL

TIE

A. Layout sketch of busway run B. All necessary dimensions C. Positions of equipment (fronts or rears) D. Phasing of existing equipment or equipment by others E. Location of walls (if applicable) F. Location of floors (floor to floor dimensions) G. Wall thickness (if applicable) H. Floor thickness I. Location of roof (if applicable) J. Roof thickness (if applicable) K. Special requirements noted on busway sketch (e.g., special lugs, critical dimensions) L. Indicate appropriate service device (e.g., tap box, service head, xfmer. tap, bussed) M. Equipment details if connecting busway to other than Square D equipment N. Indicate location of plug-In busway on sketch O. Indicate the side of the busway that the plug-in units are to be mounted P. Indicate if there are any curbs where busway passes through floors Q. Curb thickness (in addition to the floor thickness) R. Indicate type of vertical hangers (spring or fixed) S. If connecting to existing I-LINE I, indicate bolt or slot connection T. If connecting to other than Square D busway, send a piece of that busway to Oxford U. Switchboard identification markings noted on busway sketch 19972001 Schneider Electric All Rights Reserved16

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Busway Systems

Application Data

The Four Types of Busway Runs

There are four major types of busway applications. Figures 1 4 illustrate the basic systems.

Service Entrance RunFigure 1 is a typical service entrance run from a utility transformer to a switchboard. Cables connect directly to the busway. (Generally a combination outdoor-indoor application.)

Figure 1

Plug-In Type Vertical RiserFigure 3 is a simple plug-in riser fed by a switchboard. (Always an indoor application.)

Figure 3

Plug-In Type Horizontal RunFigure 2 is a simple plug-in run fed by a switchboard through a tee. (Always an indoor application.)

Figure 2

Feeder Type Tie Run

Figure 4 is a typical feeder run between two switchboards. (Generally an indoor application.)

Figure 4

XFMR

RearofSWBD

Wall

Front

of

SWBD

3rd Floor

Plug-in UnitsMount This Side

2nd Floor

TOP

TOP

TOP 1st Floor

FrontofSWBD

Top

Top

Rear

of

SWBD

Front

of

SWBD1709/01 19972001 Schneider Electric All Rights Reserved

Busway Systems

Application Data

Service Entrance Runs

I-LINE II busway can be used as a service entrance conductor to bring power from a utility transformer into a distribution switchboard. Cable or solid bussing is used to connect to the transformer.

When the transformer is connected to the busway using cables, the governing electrical code may specify height clearance requirements for the cables.

Figure 5: Typical connection of transformer to busway using cables

Figure 5 illustrates the dimensions to be considered when planning this type of run.

Service Heads

If the busway specifications or local utility require that for the service entrance cable-to-busway termination be enclosed in a weatherproof box, then a service head should be ordered.

Figure 6: Typical vertical service head application

If the flatwise busway elevation is too low to allow a cable connection that would comply with the electrical code, another solution is the Vertical Service Head (29SV). The vertical service head can be attached to busway that exits the rear of the switchboard (see Figure 6) and is turned upward, or can be attached to busway that exits the top of a switchboard and penetrates the roof utilizing a drip flange and roof collar (see Figure 7 on page 19).

X

For X dimensionsrefer to (NEC Article 230-24).

X

X

X

Vertical servicehead

28.00711

29.00737

X

X

XX

Refer to code for minimumheight requirements.

Ground level

Outdoor

All "X" dimensions must be known.Switchboard phasing must also be known.

Indoor

Dual Dimensions: INCHESMillimeters 19972001 Schneider Electric All Rights Reserved18

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Busway Systems

Application Data

Figure 7: Vertical service head penetrating a roof

If a vertical service head extends through a roof, the roof must be sealed around the busway. To do this, a fixed collar must be factory assembled onto the section of busway that penetrates the roof. The contractor can then flash from the collar to the roof. A roof flange kit can be ordered from the factory to make the flashing job easier. The kit consists of a drip flange and a roof collar. When installed, the roof collar must be sealed to ensure that no moisture gets indoors. The roof flange kit will accommodate a roof slope up to one inch per foot. See Detail A in Figure 7.

Figure 8: Transformer tap for one three-phase transformer

Figure 9: Transformer tap for three single-phase transformer

Transformer Taps

A transformer tap performs the same function as a service head, except that the lugs and bussing to which the service entrance cables are connected are not enclosed in a weather-proof enclosure.

A Flatwise Service Head (71SB) with the box removed is therefore a Transformer Tap (71SF). A (71SF) is a transformer tap for one three-phase transformer. Figure 8 illustrates a typical 71SF service entrance run.

If three single-phase transformers are supplied by the utility to deliver power to the customer, a separate transformer tap has been designed for this application. This transformer tap is known as a TTF and is shown in Figure 9.

Note: Integral weather seal supplied where busway passes through roof. All "X" dimensions must be known.

Outdoor

Indoor See Detail A

X

Switchboard

Drip flange

15.00381

28.00711

Roof

Roofcollar

6.00152

8.00203

Detail A

6.00152

X

X

Dual Dimensions: INCHESMillimeters

Indoor

Outdoor

Cables

Switchboard

All "X" dimensions must be known.

Wall

Transformer

71.001803

4.00102

minimum

X

X

X

X

Dual Dimensions: INCHESMillimeters

All "X" dimensions must be known.Wall

X

X

Switchboard

120.003048

XFMR

XFMR

XFMR

X

X

Dual Dimensions: INCHESMillimeters1909/01 19972001 Schneider Electric All Rights Reserved

Busway SystemsFigure 10: Measurements needed for bussed transformer connection (throat type)

Transformer tank wall

"X" Number anddiameter of holes

LV Spade Detail"X" Thickness

X

X X X

X XX

X

outdoor ground level will be at different heights.

All X dimensions mustbe known.Application Data

Bussed Transformer Connections

If required, the factory can provide a bussed transformer connection. This type of connection will include flexible connectors from the low voltage spades of the transformer to the busway connectors. These flexible connectors are used to allow for busway expansion and contraction on the low voltage spades. Positioning of these flexible connectors is critical for proper alignment between the busway and transformer.Bussed transformer connections are usually made to two types of transformers. One type has a low voltage throat as shown in Figure 10, and the other is a padmount type with a low voltage compartment shown in Figure 11 on page 21.

PhasingWhen a bussed transformer connection is to be used, it is essential that the phasing of the transformer and of the switchboard it supplies be properly coordinated. It is sometimes best to let the manufacturer coordinate the phasing. Simply supply the name of the transformer manufacturer and phasing details of the low voltage side.

Other Service Entrance Connections

Occasionally, the customer or local utility will require a service entrance connection that differs from our standards. In this case, be sure to inform the factory of any special dimensions, such as required height of service head from ground or floor, spacing between phase bars, number and type of lugs, distance from lugs to wall, phasing, etc.

Indicate number of holes,diameter of holes, and spacing between holes.

Top View of TransformerLV throat

LV spades

CL of Bushing

Outdoor

Indoor

Top of transformer

CL Bushing

Edge ofthroat collar

Side View ofTransformer

XX X

X

X

X

X X X X

XX

X

X

X

X

X X

X

Front of switchboard

Front

Information Needed for Transformer Connection

Note: Often the floor level and 19972001 Schneider Electric All Rights Reserved20

09/01

Busway Systems

Application Data

Figure 11: Measurements needed for bussed transformer connection (pad mount type)

Transformer tank wall

LV spades

"X" Number anddiameter of hole

LV Spade Detail

"X" Thicknessof spade

Switchboard

Front of transformer

Note: Often the floor level and outdoor ground level will be at different heights.

All "X" dimensions must be known.

Note: In the low voltage compartment, the busway should be oriented so that the phase bars are parallel with the transformer LV spade.

Outdoor

LV spades

Front View of Transformer

Side View of Transformer

Indoor

XX

X

X

X

X

X

X X X X

X

X X

X X X

X XX

X

X

X

X

X

CLCL2109/01 19972001 Schneider Electric All Rights Reserved

Busway Systems

Application Data

Plug-in Busway Horizontal RunPlug-in busway is used as a means of bringing power from a distribution switchboard to multiple loads throughout a building or manufacturing facility.

PhasingA typical I-LINE II plug-in run is shown in Figure 12. The phasing shown on the plug-in busway is GABCN top to bottom, with the top located as shown for a horizontal run. This phasing arrangement must always be followed so that proper phasing of the plug-in units will be ensured (see Detail A). Because this

busway phasing must be followed, it is the busway that will determine the phasing of the switchboard.NOTE: Plug-in busway has the integral ground bus plug-in jaw on the top side only.

Identification

When submitting busway run sketches for review, ensure that the plug-in busway sections are marked (P).

XP

P

P

P

Rear of switchboardP

P

NCBAG

All X dimensions must be known. Indicates plug-in devices.

Unfusedreducer

Endclosure

Endclosure

GABCN GA

BCN

Plug-inunit

X

X X

X

X

X

X

X

X

CL

Top

Top

Top

Top

Top

Detail AHook-Swing Mounting

Notches in top rail position unit.Hooks support weight of deviceduring installation.

Top

GABCN

Figure 12: Measurements needed for a typical plug-in type run 19972001 Schneider Electric All Rights Reserved22

09/01

Busway Systems

Application Data

Plug-in RisersI-LINE II plug-in busway can be utilized for the entire vertical riser. There is no need to use feeder busway to penetrate the floors. This feature enables the use of more plug-in openings per floor of the riser. (Plug-in risers under 800 A require internal barriers where the busway passes through a floor.)

Dimensions

The riser in Figure 13 has been fully dimensioned. Note that feeder style busway has been used out of the switchboard and the two 120-inch (3048 mm) sections of plug-in style busway on the second and third floor do not have a joint located in or near the floor. Refer to page 25 for a discussion and detail of joint accessibility requirements.Figure 14 shows typical dimensions that should be known to ensure an accurate installation: floor-to-floor height, floor thickness, exact layout of multiple run riser, closet dimensions, the type and quantity of plug-in tap units per floor, which side of the busway the units should mount on, and (if necessary) the desired height of the units from the floor.

Figure 13: Typical layout 800 A riser

Figure 14: Typical information needed for riser

Riser Installation and PhasingCircuit breaker type and the 30 A, 60 A, and 100 A fusible type plug-in units can be mounted on either side of the busway in riser installations.

When fusible type plug-in units are being supplied, the location of the plug-in unit determines the phasing of the busway. NEC Article 380-6 and CEC Article 14.502 state: Single throw knife switches shall be mounted so that gravity will not tend to close them. It is essential that the busway be oriented with the correct side available for the insertion of the units.

To determine the correct busway orientation (based on where the plug-in units mount for your installation), please contact your local representative for assistance and coordination.

Front ofswitchboard

Feederbusway

Plug-inbusway

3rd Floor

End closure

1st Floor

2nd Floor

120.003048

120.003050

1.0025

27.00686

15.00381

15.0038112.00

305120.00

3048

83.002108

.5013

150.003810

105.002667

192.004877

Top

Top

NCBAG

NCBAG

Dual Dimensions: INCHESMillimeters

Front ofswitchboard

Plug-inunits mountthis side

2nd Floor

End closure

1st Floor

3rd Floor

All X dimensionsmust be known.

X

X

X

X

X

X

X

X

X

NCBAG

NCBAG2309/01 19972001 Schneider Electric All Rights Reserved

Busway Systems

Application Data

Figure 15: Correct orientation of riser busway

Figure 15 shows the correct mounting and phasing of the riser busway and plug-in unit. It is IMPERATIVE that the face labelled TOP be installed as shown on the installation drawings provided with your project.

Special Manufacturers Recommendation

NEC requires a waterproof curb to be installed at each floor opening where busway passes through (see Figure 16). An unprotected floor opening can act as a funnel for plumbing leaks, sprinkler system leaks, fluid spills, and other types of contamination.

The cost of removing and replacing a contaminated busway length far exceeds the cost for including a waterproof curb when the floors are poured.

Once busway is installed through a floor opening, the remaining unused area should be filled to prevent smoke from passing floor-to-floor (chimney effect) in case of fire in the building. Some recommended materials available are fire rated foam and caulk. Grouting is also acceptable, but must be applied in a very dry form to prevent water and contaminants from entering the busway once the grouting cures and the water leeches out. Check with your local inspector to determine the appropriate materials to be used in filling the void around the busway.

Plug-In UnitsWhen entering an order, the factory must know not only which side of the busway the plugs will mount on, but also the type and quantity of plugs to be used on each floor. Also, notify the factory if the plugs need to be mounted at a certain height from the floor.

HangersSpring hangers are recommended for riser applications. When properly installed and maintained, spring hangers compensate for expansion and contraction of the busway, as well as shrinkage of the building. In riser applications, support for busway must be provided at intervals not exceeding 16 ft (488 cm).

ON

OFF

NCBAG

Top

Floor

Busway

Curb

4.00102

Dual Dimensions: INCHESMillimeters

Figure 16: Waterproof curb recommended at floor opening 19972001 Schneider Electric All Rights Reserved24

09/01

Busway Systems

Application Data

Feeder Runs

Feeder type runs are normally used for distributing power to loads that are concentrated in one area. Typical connections are switchboard-to-switchboard tie runs (see Figure 17), or a switchboard feeding a remote motor control center (MCC).

Figure 17: Measurements needed for feeder type run

Figure 18: Joint accessibility requirements

Busway Through Walls and FloorsWhen 800 A5000 A busway extends through a wall or floor, feeder or plug-in busway can be used. For runs under 800 A, plug-in busway will be used throughout. In all cases, wall or floor location must be specified.

According to CEC Article (12.2006) and NEC Article (364-4), busway must be installed so that supports and joints are accessible for maintenance purposes after installation. This implies that no part of the tie channel can be inside the wall. Therefore, the distance from the center line of the joint to the wall must be greater than the distance from the center to the edge of the tie channel (see Figure 18). If the dimensions of the tie channel cannot easily be determined, it is best to keep the joint at least 12 inches (305 mm) from wall. This will ensure proper joint clearance for any type of busway passing through a wall or floor.

XX X

X

X

Front of Switchboard

A

Wall

X

Front of Switchboard

B

X

NCBAG

GABCN

B

Edge oftie channel

Dimension B must begreater than 8 inches (203 mm).

Tie channel

Wall

CLJoint

8.00203

Dual Dimensions: INCHESMillimeters2509/01 19972001 Schneider Electric All Rights Reserved

Busway Systems

Layout and Measurement

Layout And Measurement of Busway Installations

Laying out and measuring a busway job does not require specialized tools or skills. The following list of tools will generally be sufficient: 100 ft (3048 cm) tape measure Plumb bob/chalk line 25 ft x 1 in. (762 cm x 25 mm) tape measure Felt tip marker or crayon 6 ft (183 cm) wood ruleLets assume you want to feed a new motor control center (MCC) with busway from a new distribution switchboard. Using illustrations, well go step by step through the layout process to determine the busway orientation and dimensions. When completed, we will have a single line isometric drawing showing the proposed busway layout.

Known Information

From the bid documents, specifications, and/or factory drawings, the following information is known: Busway is to be 1600 A, 34W 50% GND aluminum feeder

busway. (Width is determined to be 8.84 in. (225 mm). Switchboard is 7 ft x 7 1/2 in. (213 cm x 191 mm) high, 3 ft

(91 cm) wide, and 2 ft (61 cm) deep. Busway connection to be in top center.

Motor control center is 7 ft x 7 1/2 in. (213 cm x 191 mm) high with a 1 ft (30 cm) additional height pull box for busway connection; 20 in. (508 mm) wide; 20 in. (508 mm) deep. Busway connection is in top center.

Bottom of busway (B.O.B.) to be installed 16 ft (488 cm) above finished floor (A.F.F.) unless obstructed.

1. Determine the physical size of the busway housing.This information lets you know how far to stay away from obstructions. In our example Figure 19, the busway is 8.84 in. (225 mm) wide and 5.88 in. (149 mm) high (9 in. x 6 in. (229 mm x 152 mm) nominal).

Figure 19

2. Review the area where the busway could be installed (if not already specified). Note special conditions such as building expansion joints, steel changes, HVAC equipment, and plumbing lines.

3. Measure all dimensions from fixed points.Measure dimensions such as columns, walls, or other building structures. Try to leave at least 4 in. (102 mm) between the busway and any obstructions. Figure 20 on page 27 shows the switchboard and MCC locations, the obstructions, and the dimensions to fixed points.

4. Start dimensional layout from the fixed end.Sketch the proposed busway routing, noting elevations and obstructions (see Figure 21 on page 27).

5. Route the busway above the bottom chord of the building steel, unless specified. For industrial applications, this protects the busway from damage by forklifts, cranes, etc. The busway must be supported by drop rods or from below. Do not route busway where it cannot be adequately supported.

6. When selecting the elevation for plug-in busway, remember that overcurrent devices (plug-in units) may require different mounting clearances.Referring to the sample busway layout, (see Figure 21), enough information is known to tabulate the amount of busway footage needed and the required fittings (e.g., flanged ends, elbows). A copy of the figure could help your local sales representative with pricing your job, and also could be forwarded to the factory to aid in preparation of approval or record drawings.

TopGABCNG

8.84225

5.88149

1600 A Al

Dual Dimensions: INCHESMillimeters 19972001 Schneider Electric All Rights Reserved26

09/01

Busway Systems

Layout and Measurement

Figure 20: Plan view switchboard, MCC, and obstructions

Figure 21: Proposed busway layout

CL

CL

CL

10.00254

45.001143

36.00914

360.009144

240.006096(Typical)

50.001270

4.00102

A

B

6

C

5

GABCN Front

ofswitchboard

24.00610

73.001854

4.00102(Typical)

12.00305

Front ofMCC

NCBAG 20.00508

20.00508

20.00508

30.00762

Columns12 in. x 12 in. (305 mm x 305 mm)

(Typical)

3 in. (76 mm) Steam lineBottom of Pipe (B.O.P.)

16 ft (488 cm) Above Finished Floor (A.F.F.)

6 in. (152 mm) Condensate lineB.O.P. 16 ft (488 cm) A.F.F.

North

Dual Dimensions: INCHESMillimeters

CL

CL

10.00254 45.001143

Rise up8 ft 7 in. (144 cm 178 mm) (B.O.B. 4877 A.F.F.)

(E 4953 A.F.F.)

360.009144

240.006096

50.001270

4.00102

A

B

6

C

5

Frontof

switchboard

24.00610

Offset up12.00

305

73.001854

Offset down12.00

305

12.00305

18.00457

Drop down91.00

2311

North

CL

Front ofMCC

NCBAG 20.00508

20.00508

20.00508

30.00762

4.00102(Typical)

GABCN

3 in. (76 mm) Steam lineBottom of Pipe (B.O.P.)

16 ft (488 cm) Above Finished Floor (A.F.F.)6 in. (152 mm) Condensate line

B.O.P. 16 ft (488 cm) A.F.F.

Dual Dimensions: INCHESMillimeters

Bottom of Busway (B.O.B.) 16 ft (488 cm) A.F.F.

B.O.B. 17 ft (518 cm) A.F.F.

Columns12 in. x 12 in. (305 mm x 305 mm)

(Typical)2709/01 19972001 Schneider Electric All Rights Reserved

Busway Systems

Installation, Special Features, and Services

Installation Recommendations

To make the busway installation proceed as quickly and efficiently as possible, a few preliminary steps should be taken.

1. Familiarize yourself with the busway routing. If record drawings were supplied by the factory, have a copy accessible to the installers.

2. Inspect busway for damage when received. Store busway in a clean, dry location.

3. Have the following recommended tools available for the busway installation:

1/2-in. (13 mm) nut driver or socket and rachet Straight blade screwdriver torque wrench or breaker bar with 5/8-inch (16 mm) head 3/4-in. (19 mm) socket for torque wrench or breaker bar busway assembly tool (AT-2) for 800 A5000 A (provided by

Square D) A level Tape measure or 6 ft (488 cm) wood rule Busway insulation tester (megger, 1000 V recommended)4. Carefully read the installation instructions for all devices

and NEMA Publication BU1.1-2000 provided with the busway before installing any of the equipment. This will help ensure proper installation and operation procedures are followed for the busway system being installed. Note the instructions call for the busway to be meggered before and after installation.

5. Install busway hangers and supports. The most common method of supporting the busway hangers is threaded drop rods (or all thread) which the installer must supply.

6. Anticipate the weight of the objects being installed so the necessary lifting devices and manpower are available.

7. If any problems are encountered or questions arise, contact your local representative.

8. Once the installation of the busway is complete, the NEMA Publication BU1.1-2000 should be delivered to the facility owner for his or her use in operating and maintaining the busway system.

Painting Installed Busway Systems A busway system, which includes plug-in units, may be painted after installation. All precautions, however, must be taken to prevent the paint from coming in contact with conductors and insulation, and all nameplates and labels (safety labels, serial number labels, UL Labels, etc.) remain visible and legible.

Hanger SpacingMaximum support intervals include:

Vertical mounting indoor16 ft (488 cm) outdoor5 ft (152 cm)

Horizontal mounting indoor10 ft (305 cm) outdoor5 ft (152 cm)

Maintenance Recommendations

NEMA Publication BU1.1-2000 is provided with each busway project as a guide for proper installation, operation and maintenance of busway products. This publication addresses such areas as inspection of all electrical joints and terminals for tightness, prevention of entry of water and contaminants into the busway, instructions for what to do if water and contaminants do enter the busway, and other maintenance topics. This publication is also available upon request by contacting your local representative.

HAZARD OF ELECTRIC SHOCK, BURN OR EXPLOSION Electrical equipment should be serviced only by qualified

electrical maintenance personnel, and this instruction bulletin should not be viewed as sufficient instruction for those who are not otherwise qualified to operate, service, or maintain the equipment discussed. Although reasonable care has been taken to provide accurate and authoritative information in this bulletin, no responsibility is assumed by Square D for any consequences arising out of the use of this material.

The successful operation of busway depends upon proper handling, storage, installation, operation, and maintenance. Neglecting fundamental installation and maintenance requirements may lead to personal injury as well as damage to electrical equipment or other property.

Follow safety related work practices, as described in NFPA 70E, part II, at all times.

Hazardous voltages in electrical equipment can cause severe personal injury or death. Energizing busway for the first time after initial installation or maintenance is potentially dangerous. Unless otherwise specified, inspect and perform preventive maintenance only on busway and equipment to which power has been turned off, disconnected, and electrically isolated so that no accidental contact can be made with energized parts.

Failure to follow these instructions will result in death, severe personal injury, or equipment damage.

DANGER 19972001 Schneider Electric All Rights Reserved28

09/01

Busway Systems

Installation, Special Features, and Services

Other publications we recommend to help ensure the highest quality of product performance are as follows:

NFPA 70National Electrical Code (U.S.)NFPA 70BMaintenance of Electrical Equipment

NEMA BU1Busway Standard published by theNational Electrical Manufacturers Association

CSA C22.1Canadian Electrical Code, Part 1

Special Busway Construction

This section outlines requirements for busways with features other than our standard.

Special Paint

I-LINE busway can be provided in colors other than ANSI 49 gray for a price add-on. The special color requested should be specified by an ANSI color code at the time of order entry. With typically lengthened lead times for special color parts, it is imperative to provide this information as early as possible in the order process so delivery commitments can be met.

Low Current Density BuswaySome customers require a lower current density busway than our standard for rigorous duty in their installation. We have developed a range of busway for the most commonly requested current density of 1000 A per square inch for copper busway. If you require this current density for your installation, specify it, and we can meet your need. If you have requests for another specific current density, contact your local representative.

Riser Plug-in BuswayWe also offer an I-LINE II plug-in busway specifically designed for installation in riser closets of high-rise buildings. This plug-in busway has a plug-in door on the front side that faces out into the room. The back of the busway, facing the wall is blanked off with a feeder bus side rail.

This design provides a plug-in busway ideally suited for riser cabinets and gives the customer only the necessary plug-in openings. The catalog number for this device is the same as our plug-in busway, except an R is substituted for the P. (Example: if the standard plug-in busway prefix is AP2512G, the riser busway prefix is AR2512G).

Drip Resistant to IP-54

Some busway is located in indoor locations that are subject to occasional water, such as roof leaks or sprinklers. While this application does not require the full protection of outdoor busway, additional protection is needed for the indoor busway. This is where the Drip Resistant feature could be used. This added feature to the busway is tested to the International IEC-529 standard and is rated as IP-54. This rating specifies protection from dust (limited ingress permitted with no harmful deposits) and water (splashed from all directions with limited ingress permitted).This product is available as an option with indoor plug-in and feeder busway. It is identified by the addition of M54 at the end of the standard catalog number.2909/01 19972001 Schneider Electric All Rights Reserved

Busway SystemsInstallation, Special Features, and Services

19972001 Schneider Electric All Rights Reserved30

09/01

Services

We pride ourselves in providing excellent service to our customers the world over. We offer a wide range of services to make the use of I-LINE busway as simple and easy as possible. A summary of these services follows:

Busway Measuring and Layout ServiceWe can provide full site measuring and coordination of a busway installation. This service is ideal for large complicated projects requiring close coordination with other services. This service must be requested at the time of specification and order entry. Refer requests for this service to your local representative.

Emergency ServiceTrained and qualified busway personnel are on call 24 hours daily to assist in your emergency busway needs. Call 1-888-SQUARE D (1-888-778-2733) any time.

Missing Link ProgramThe Missing Link program is designed specifically to help a customer correct last minute changes to a project using busway. Those changes could include an unplanned obstruction requiring the busway to be rerouted, incorrect measurement of the busway run, or the need to order additional pieces to supplement busway previously ordered. The program applies to the United States, Canada, and Mexico, and guarantees shipment of factory-built busway in five to seven working days or we pay for the premium freight. The program applies to I-LINE II (800 A5000 A) indoor and outdoor feeder busway straight lengths and elbows (90, offset, and double). Plug-in busway is not included in the program. Straight lengths are available in one-inch increments from 16120 in. (4063048 mm). The program is limited to a maximum of four pieces of busway per run and twenty pieces per order. For complete details of the program, contact Square D at 1-888-SQUARE D (1-888-778-2733).

Busway Quick Ship ServiceAn extensive selection of busway is available for direct shipment from the Oxford Distribution Center. This service will allow you to order your busway today and have the order shipped within two days. There is no need to wait for standard busway devices. The following categories of busway devices are included in the quick ship program. 800 A2000 A copper I-LINE II indoor feeder and

plug-in busway 800 A3000 A aluminum I-LINE II indoor feeder and

plug-in busway 225 A600 A copper and aluminum I-LINE plug-in busway.

All of the above in both: three-phase, three-wire three-phase, four-wire

How To Properly Measure Your Missing Link(s)All Missing Link dimensions should be measured to the nearest whole inch from centerline of joint to centerline of joint, or centerline of joint to centerline of busway.As shown in Figure 22 Diagram A, the centerline of the joint is located at the joint bolt on the end with a joint-pak installed. If the joint-pak is not installed, the centerline of the joint is one inch (25 mm) from the end of the bus bars.If it is necessary to measure an elbow, the dimensions X and Y (shown in Figure 22 Diagram B) are all thats needed. Be sure to measure from centerline of joint (as described above) to centerline of busway housing. You must also specify whether an edgewise or flatwise elbow is required. The table on page 49 lists the standard minimum elbow dimensions for each amperage.

Figure 22

CL

CL Joint bolt

Endof bars

X

A - Straight LengthsWithoutjoint pak Withjoint pak

CL JointCL Joint

CLBus

CL Bus

B - Elbows Withjoint pak

Without joint pak

YX

Endof bars

1.0025

1.0025

Dual Dimensions: INCHESMillimeters

Busway Systems

Electrical Data

Electrical Data

Standards: UL857 (File Number E22182); CSA C22.2 No. 27-1973 (File Number LL-61778); IEC 439 Parts 1 and 2

Systems: ac33W, 34W, 12W, 13W. All neutrals are 100% capacity dc2-pole

Voltage: 600 Volts ac/dc, 50 Hz and 60 Hz Ground: 50% capacity as standard for 800 A5000 A, as an

option on 225 A600 A Enclosure: Indoor and outdoor

NOTE: 225 A600 A busway are connected in series with a Class J or T fuse; 800 A5000 A are connected in series with a Class L fuse. All ratings are tested in compliance with UL/CSA standards. All ratings apply for three-pole and four-pole busway.

Impedance Values

Short Circuit Ratings: UL Three-cycle Test (KA, RMS Symmetrical)AmpereRating

Aluminum CopperAOF2AF2

AO